Structural elements and method for fabricating structural elements

ABSTRACT

A composite panel structure includes a flange beam assembly including: a web assembly; and a first flange assembly attached in an essentially perpendicular fashion to the web assembly. The composite panel structure further includes at least two panel assemblies. Each panel assembly includes: a foam layer; a first high-density material layer secured to the foam layer; and at least one recess configured to receive at least a portion of the first flange assembly.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority of U.S. Provisional Application No. 60/594,948, entitled APPARATUS AND METHOD FOR FABRICATING STRUCTURAL ELEMENTS FOR BUILDINGS, which was filed on 21 May 2005; the entire contents of which are herein incorporated by reference.

FIELD OF DISCLOSURE

The present invention relates to structural elements and methods for fabricating structural elements for buildings and more specifically to insulating foam-concrete structural elements.

BACKGROUND

Many types of fabrication techniques are used in the construction industry. The types of materials and systems used depend on several factors. For example, the size of the building will require different types of construction material based on the number of floors and other considerations. Local building codes also dictate specific types of construction materials. This will vary from area to area depending on the nature of local factors such as climate. In areas such as the southeastern United States, which are subject to hurricanes, local building codes may require that any new structures meet minimum local wind resistance standards. Likewise, areas subject to heavy snowfall may have codes with rigid requirements for ceiling strength to support the weight of snow on a roof. Of course, this can drastically affect the types of materials selected for construction from one area of the country to another. It would be desirable to have a building construction system that would satisfy building codes in a wide range of areas. It would also be desirable to have a construction system that can be used not only for smaller residential buildings, but also for larger commercial buildings which may have a requirement for high strength to support the weight of multiple floors, and other structures, such as retaining walls.

Building requirements vary from one part of the country to another due to a variety of factors. Typically each locality will have their own unique requirements. In contrast to the southeastern United States, where high winds are an important factor, other locations, such as the Southwest, are subject to large-scale fires that occur on a regular basis. As a result, the local building codes in that area of the country may have more stringent requirements regarding fire resistance than other locations across the country.

Environmental and public policy issues are other important issues related to construction. Due to a concern for environmental issues such as fuel conservation, proper insulation of homes has become a significant issue nationwide. In addition to conservation issues, fuel conservation is also an important issue for individual family finances as well as for national policy/security reasons. In response to the need to conserve fuel, many insulation systems have been developed to increase the thermal efficiency of homes and commercial buildings. Materials such as fiberglass and foam insulation have been developed that provide superior insulation characteristics that protect a building from both heat and cold. While many materials work very well in terms of providing insulation, some have been known to have one or more drawbacks. For example, the cost of adding insulation to buildings and other structures may be expensive. Likewise, some insulation materials, such as formaldehyde foam, which was originally found to be very effective as an insulation material, was later found to be toxic and its use was banned. It would be desirable to have an effective method of insulating buildings while maintaining low costs, and at the same time providing a high quality system that does not provide any health hazards.

Another issue related to building construction is the use of multiple technologies. In a conventional construction project, many components of a building use unique structural elements that are based on different technologies. It would be desirable to have a technology that can be used to construct a variety of structural elements to take advantage of the economic benefits of redundancy.

While the prior art has provided numerous construction techniques and numerous construction materials, it has failed to provide a single construction technique that can be used across a variety of structural entities, such as roof trusses, sub-flooring, building walls, seawall bulkheads, highway privacy walls, and other like structures, and thereby allow construction projects to be completed with the benefit of redundant and easy to use materials.

SUMMARY OF DISCLOSURE

According to an aspect of this disclosure, a composite panel structure includes a flange beam assembly including: a web assembly; and a first flange assembly attached in an essentially perpendicular fashion to the web assembly. The composite panel structure further includes at least two panel assemblies. Each panel assembly includes: a foam layer; a first high-density material layer secured to the foam layer; and at least one recess configured to receive at least a portion of the first flange assembly.

One or more of the following features may also be included. The foam layer may be at least partially constructed of a vinyl acetate-ethylene copolymer. The first high-density material layer may be a poly-urea material layer. The first high-density material layer may be a cement-based material layer. The composite panel structure may be selected from the group consisting of: a building wall panel structure; a roof panel structure; a ceiling panel structure; a floor panel structure; a privacy wall panel structure; a sea wall panel structure; and any combination thereof.

The composite panel structure may include a second high-density material layer. The foam layer may be disposed between the first and second high-density material layers. The flange beam assembly may include a second flange assembly attached in an essentially perpendicular fashion to the web assembly.

According to another aspect of this disclosure, a method of fabricating a composite panel structure includes providing a flange beam assembly including a web assembly and a first flange assembly attached in an essentially perpendicular fashion to the web assembly. A layer of foam is provided that includes at least one recess configured to receive at least a portion of the first flange assembly. A first high-density material layer is disposed onto the layer of foam.

One or more of the following features may also be included. The layer of foam may be at least partial constructed of a vinyl acetate-ethylene copolymer. The composite panel structure may be selected from the group consisting of a building wall panel structure, a roof panel structure, a ceiling panel structure, a floor panel structure, a privacy wall panel structure, a sea wall panel structure, and any combination thereof. The first high-density material layer may be a poly-urea material layer. The first high-density material layer may be a cement-based material layer. The composite panel structure may include a second high-density material layer. The foam layer may be disposed between the first and second high-density material layers. The flange beam assembly may include a second flange assembly attached in an essentially perpendicular fashion to the web assembly.

The invention can be implemented to realize one or more of the following advantages. The composite system provides building structures with lighter weight, superior sound and thermal insulation, improved strength and improved fire safety. The structure may be fabricated on site or pre-fabricated at a factory.

Further still, the invention provides a composite building surface which has a wide variety of applications. In particular, it is not limited to a particular portion of the structure as many structural elements are. The invention presented herein produces laminar structure that can be used in a wide variety of surfaces, including roofs, walls, and floors of the building. In addition, it can be used for other structures such as seawalls, highway privacy walls, or other like structures.

An advantage of using a laminar structure is that the resulting structure exhibits many of the desired qualities of each of the laminate's components. In particular, the structure disclosed herein provides lightweight structural elements having the strength of concrete, and, in addition, structural elements that have superior insulation qualities for both sound and thermal insulation.

In building walls, the outer shell provides substantial structural strength which will satisfy local building codes for factors such as wind resistance, fire resistance, and the ability to support the weight which may be applied by floors above. In addition, the inner core provides a substantial increase in the insulating characteristics of the wall segments. The resulting laminated wall structure produces a wall structure with high strength and excellent insulating characteristics. Further, since the inner foam core of the wall structure weigh substantially less than the outer concrete shell, the wall segments will be lighter and easier to maneuver into place.

Further, all of these elements can be combined into prefabricated units to rapidly assemble a dwelling. Likewise, due to the reduced weight of the structural elements that comes as a result of the foam's light weight, substantial sections of a building or other construction project can be fabricated at factory locations under controlled conditions, and then shipped to the job site for assembly.

Also, the foam layer provides thermal insulation, provide some flexibility which may prevent cracking of the concrete, and also creates a vapor barrier. In addition, the foam is a fire retardant. As a result, in the event of a fire the foam would, at a minimum, slow down the spread of the fire and potentially reduce the extent of fire damage.

Other features and advantages of the invention are apparent from the following description, drawings and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a privacy or barrier wall according to an embodiment of the invention;

FIG. 1B is a perspective view of a the privacy or barrier wall of FIG. 1A as used in an embodiment of the invention;

FIG. 2 is side cut-away view of a concrete floor fabricated according to an embodiment of the invention;

FIG. 3 is a front view of a house including concrete wall panels according to an embodiment of the invention;

FIG. 4 is a side cut-away view of a foam/concrete roof surface according to an embodiment of the invention;

FIG. 5 is a side cut-away view of metal I-beams with foam panel according to an embodiment of the invention;

FIG. 6 is a perspective view of the metal I-beams with foam panel of FIG. 5; and

FIG. 7 is a flowchart of a method of fabricating a composite panel structure.

DETAILED DESCRIPTION

Referring to FIG. 1A, a segment 1 of a privacy (or barrier) wall includes an outer concrete shell 2 that surrounds an inner foam core 3. When used as part of a privacy wall, segment 1 provides a durable outer shell 2 that is fabricated from concrete and allows a structure to last a long period of time. The foam core 3 is protected by the outer concrete shell 2. The foam core 3 provides several advantages over solid concrete wall segments that are typical of the prior art. One advantage provided by segment 1 is that due to the lighter weight created by the foam core 3, it is less expensive to transport prefabricated segments 1 from a factory to the job site. In addition, it is also easier to put the segments 1 into position due to their lighter weight. Another important advantage provided by the invention is that the foam core 3 provides better sound insulation than the outer concrete shell 2. Since privacy walls are usually constructed to protect residential neighborhoods from traffic noise, the sound insulating properties of the foam core 3 enhance the peace and enjoyment of individuals who live near them.

In addition to concrete, durable outer shell 2 may be constructed of a rigid polymer material, such as polyurea (i.e., the result of a chemical reaction between an isocyanate and an amine, such as the reaction between an MDI or HDI pre-polymer with amine-terminated resins).

The foam used by the invention may be made from a mixture of vinyl acetate-ethylene copolymer, in combination with clay and a vinyl acetate monomer. More specifically, the vinyl acetate-ethylene copolymer (CAS # 2493 7-78-8) preferably comprises a maximum content of 90% of the foam, the clay comprises a maximum content of 10% of the foam, and the vinyl acetate monomer (CAS # 108-05-4) comprises a maximum content of 0.2% of the foam. The vinyl acetate-ethylene copolymer powder used to make the foam can be mixed at the site with the other ingredients, or premixed at the factory. In a preferred embodiment, the ingredients used to fabricate the foam are premixed at the factory to ensure that the proper quantities of each ingredient are used.

Additives may be mixed in with the cement that allow for better adhesion of the cement to the foam. Examples of these additives include “CATEXOL PVA-X” (MSDS number 40785-00), which is available from a variety of sources, including the Axim Italcementi Group of Middlebranch, Ohio.

Referring to FIG. 1B, two segments 1 are secured together by a retaining post 4. During the construction process for privacy walls, the retaining posts 4 are typically installed first and then the segments are slid into place via a crane. The lightweight of the foam core 3 reduces the amount of work necessary to assemble the privacy wall.

Those skilled in the art will recognize that the same techniques and advantages that are shown above in regard to construction of privacy walls also apply to installation of similar structural elements such as seawalls.

As shown in FIG. 2, a concrete floor (or sub-floor) 9 may be fabricated from a layer of concrete and/or polyurea 6 laminated to a layer of foam 5. When the concrete and/or polyurea floor 9 is constructed, a layer of foam 5 is first installed onto a support surface 8. Examples of support surface 8 may include plywood, orientated strand board, and corrugated sheet steel, for example. In a preferred embodiment, the layer of foam 5 is approximately 0.5 inches thick. However, those skilled in the art will recognize that the thickness is not critical and may vary. For example, foam layers having a thickness of eight inches may be utilized. Once the layer of foam 5 is installed, a layer of concrete and/or polyurea 6 may be installed on top of the layer of foam 5. When the layer of concrete and/or polyurea 6 is installed, the upper surface 7 is preferably finished to form a smooth surface.

Foam layer 5 provides several advantages. It provides a layer of insulation for conserving energy and provides a layer of sound insulation to increase the quiet and enjoyment of the building. It increases safety due to the fire retardant nature of the foam 5. In addition, it provides a method of creating a lightweight flooring panel that provides the advantages of a concrete and/or polyurea surface without the disadvantage of excessive weight (which would occur without foam layer 5). In larger commercial buildings, excessive floor weight can be a significant concern.

Referring to FIG. 3, concrete and/or polyurea wall panels 13 for a house 10 may be fabricated from concrete and/or polyurea 11 with internal foam layers 12. The concrete and/or polyurea wall panels 13 may be fabricated to include windows 14 and door 15. The wall panels 13 may be fabricated in a factory setting under controlled conditions with integral foam layers 12 incorporated into the interior of the wall panels 13. This provides a highly secure structure that provides both thermal and sound insulation due to the foam layer 12. In addition, the exterior concrete and/or polyurea shell 11 of wall panels 13 provide substantial strength and fire resistance. Alternatively, exterior shell 11 may be constructed using other known building materials (e.g., plywood, oriented strand board, etc.).

Referring now to FIG. 4, a composite roof surface 16 for a house includes a composite roof surface supported by conventional roof trusses 17. A layer of foam 18 may be positioned under, and supports a layer of e.g., concrete and/or polyurea 19. The foam layer 18 reduces the weight of the roof. The resulting roof provides an extremely strong barrier in high wind environments.

As shown in FIGS. 5 and 6, another embodiment includes foam panel 20 interlocking with I-beams 21 to form a unified insulated surface. I-beams 21 may be constructed of various materials, such as steel, aluminum, magnesium, carbon fiber, plastic, and fiberglass, for example. In this embodiment, foam panel 20 may be cut via a hotwire and die such that the upper flanges 22 extending from the central plane of the I-beams 21 fits snuggly within a groove cut in foam panel 20. Likewise, lower flanges 23 extend under the cutout portion of the foam panel 20 to provide additional support.

Alternatively, lower flanges 23 may be positioned within a second groove (not shown) within foam panel 20. During fabrication of the surface, the I-beams 21 are installed by welding to a frame. Once the I-beams 21 are installed, the foam panel 20 is then slid between the adjacent I-beams 21 where it is securely held.

As can be seen in FIG. 6, the foam panel 20 is easily assembled by sliding it between the I-beams 21. In a preferred embodiment, a series of I-beams 21 may be installed on a frame, or other support mechanism, and welded together to remain securely in place. Of course, other methods of securing the I-beams 21 can be used, such as riveting, gluing, bolting, etc. Once I-beams 21 have been installed, an entire wall, floor, ceiling, or other structural elements, can then be rapidly installed by inserting the foam panels 20 between each pair of I-beams 21. For ease of illustration, the I-beams 21 are shown relatively close together. However, in practice the I-beams 21 may be spaced apart in the same manner as conventional studs. The width of the foam panels 20 are only limited by the application for which they will be used. For example, walls, ceilings, and roofs each have separate load requirements that dictate different foam panel 20 thicknesses and different distances between I-beams 21.

In a preferred embodiment, the I-beams 21 are fabricated from aluminum because they provide an inexpensive structure that is not susceptible to corrosion. However, other materials such as steel, may also be used. Once the surface is completely constructed, a surface coating of concrete and/or polyurea 24 may be applied to the surface to create the finished look of a single unified wall, ceiling, floor, or other surface. Alternatively, stucco, or any other suitable surface covering may be applied as appropriate.

While the invention has been described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in detail may be made therein without departing from the spirit, scope, and teaching of the invention. For example, the foam layer can be used for a variety of construction applications, the size and shape of structural elements made by the inventive process can vary. The invention uses a laminar structure comprised of concrete and/or polyurea, and a layer of lightweight insulating foam. The foam layer can be used as part of a two layer element, or it can be embedded as a foam core within a concrete and/or polyurea structure. An example of a two layered element would be a concrete and/or polyurea floor. When constructing flooring, a layer of foam can be installed on the sub-flooring.

The wall structure has been described as an element in a building, such as a residence or commercial building. However, it can also be used for other applications. In particular, it is very useful for fabricating privacy walls such as those used to isolate heavily traveled roadways from residential areas. Likewise, it can be used to fabricate seawall bulkheads to protect water adjacent property from erosion.

In addition to the structural elements discussed above, the invention can also be used to fabricate lightweight roof surfaces that provide a strong outer surface that is secured to the lightweight foam substrate that is in turn secured to the structural supports (i.e. trusses) on the roof.

Referring to FIG. 7, there is shown a flowchart of a method 50 of fabricating a composite panel structure. Method 50 may include providing 52 a flange beam assembly including a web assembly and a first flange assembly attached in an essentially perpendicular fashion to the web assembly, and providing 54 a layer of foam including at least one recess configured to receive at least a portion of the first flange assembly. A first high-density material layer is disposed 56 onto the layer of foam and a second high-density material layer is disposed 58 onto the layer of foam.

Accordingly, the invention herein disclosed is to be limited only as specified in the following claims. 

1. A composite panel structure comprising: a flange beam assembly including: a web assembly; and a first flange assembly attached in an essentially perpendicular fashion to the web assembly; and at least two panel assemblies, wherein each panel assembly includes: a foam layer; a first high-density material layer secured to the foam layer; and at least one recess configured to receive at least a portion of the first flange assembly.
 2. The composite panel structure of claim 1 wherein the foam layer is at least partially constructed of a vinyl acetate-ethylene copolymer.
 3. The composite panel structure of claim 1 wherein the first high-density material layer is a poly-urea material layer.
 4. The composite panel structure of claim 1 wherein the first high-density material layer is a cement-based material layer.
 5. The composite panel structure of claim 1 wherein the composite panel structure is selected from the group consisting of: a building wall panel structure; a roof panel structure; a ceiling panel structure; a floor panel structure; a privacy wall panel structure; a sea wall panel structure; and any combination thereof.
 6. The composite panel structure of claim 1 further comprising a second high-density material layer.
 7. The composite panel structure of claim 6 wherein the foam layer is disposed between the first and second high-density material layers.
 8. The composite panel structure of claim 1 wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly.
 9. A method of fabricating a composite panel structure comprising: providing a flange beam assembly including a web assembly and a first flange assembly attached in an essentially perpendicular fashion to the web assembly; providing a layer of foam including at least one recess configured to receive at least a portion of the first flange assembly; and disposing a first high-density material layer onto the layer of foam.
 10. The method of claim 9 wherein the layer of foam is at least partially constructed of a vinyl acetate-ethylene copolymer.
 11. The method of claim 9 wherein the composite panel structure is selected from the group consisting of a building wall panel structure, a roof panel structure, a ceiling panel structure, a floor panel structure, a privacy wall panel structure, a sea wall panel structure, and any combination thereof.
 12. The method of claim 9 wherein the first high-density material layer is a poly-urea material layer.
 13. The method of claim 9 wherein the first high-density material layer is a cement-based material layer.
 14. The method of claim 9 further comprising disposing a second high-density material layer onto the layer of foam.
 15. The method of claim 14 wherein the foam layer is disposed between the first and second high-density material layers.
 16. The method of claim 9 wherein the flange beam assembly includes a second flange assembly attached in an essentially perpendicular fashion to the web assembly. 